OIL & GAS EQUIPMENT | Updated May 2026 | 10 min read
What You’ll Learn in This Comparison
- The three companies’ product portfolios, manufacturing footprint, and market focus
- Where each supplier wins on engineering, certification, and aftermarket support
- Project size and customer profile fit for each company
- How buyer profile (upstream vs midstream vs refining) affects supplier selection
- Decision framework for choosing between the three suppliers for a specific project
- What questions to ask before final supplier selection
Hero Process Solutions, Zeeco, and John Zink Hamworthy are three of the most-evaluated flare and combustion equipment suppliers in the United States oil and gas industry. Operators planning capital projects in 2026 new flare installations, vapor recovery additions, OOOOb retrofit upgrades, or integrated emission control packages routinely shortlist these three. The right choice depends on project profile, operator culture, and supplier fit factors that brochure-level comparison misses. This guide walks through the substantive differences across product portfolio, engineering depth, market focus, and aftermarket support so that decision teams can choose confidently.
Hero Process Solutions, founded in 2011 and headquartered in Kellyville, Oklahoma with operations in Midland, Texas, manufactures industrial flare systems, vapor recovery, BTEX condensers, vapor combustors, thermal oxidizers, and 3-phase separators. We are profiled below alongside Zeeco and John Zink Hamworthy with a buyer-side framework for the comparison decision.
DIRECT ANSWER: Hero Process Solutions, Zeeco, and John Zink Hamworthy are three leading flare and combustion equipment suppliers serving the United States oil and gas market. Hero Process Solutions is the mid-size United States manufacturer with responsiveness, custom engineering, and Quad O Certified portfolio expanded through 2020 Tri-Point and Scorpion acquisitions, best fit for upstream and midstream operators. Zeeco is a global combustion equipment manufacturer with substantial market presence, global service network, and strong refining and petrochemical project fit. John Zink Hamworthy is a Koch Engineered Solutions company with long-standing relationships in refining and petrochemicals, global manufacturing footprint, and recognized brand position. The right choice depends on project size, market focus, and buyer’s culture-fit priorities.
1. Company Snapshot Comparison
| Attribute | Hero Process Solutions | Zeeco | John Zink Hamworthy |
|---|---|---|---|
| Founded | 2011 | 1979 | 1929 (John Zink original) |
| Ownership | Independent (Craig Rosencutter, President/CEO) | Independent privately held | Koch Engineered Solutions subsidiary |
| Headquarters | Kellyville, Oklahoma | Broken Arrow, Oklahoma | Tulsa, Oklahoma + global |
| US manufacturing | Kellyville, OK + Midland, TX | Multiple US plants | Tulsa OK + global |
| Global manufacturing | US-focused | Multiple international facilities | Multiple international facilities |
| Service area | USA primary, Permian/Marcellus/Haynesville focus | Global | Global |
| Approximate size | 50 to 200 employees, ~$32M revenue | Several thousand employees globally | Several thousand employees globally |
The three companies are very different in scale and global footprint, which directly affects project-fit and operator-relationship dynamics.
2. Product Portfolio Comparison
| Product Line | Hero Process Solutions | Zeeco | John Zink Hamworthy |
|---|---|---|---|
| Air-assist flares | Yes — A+ Series | Yes | Yes |
| Sonic flares | Yes — Coanda-profile | Yes | Yes |
| Gas-assist flares | Yes | Yes | Yes |
| Utility flares | Yes — emergency utility | Yes — UF Series | Yes |
| Portable / mobile flares | Yes — trailer-mounted | Limited | Yes — Callidus rental |
| Low flow flares | Yes — battery/solar spark | Yes | Yes |
| Vapor combustors / enclosed combustors | Yes — Quad O Certified (Tri-Point heritage) | Yes | Yes |
| Vapor recovery systems | Yes | Yes | Yes — Callidus FGRS |
| BTEX condenser systems | Yes — Scorpion BTEX | Limited | Limited |
| Thermal oxidizers | Yes | Yes | Yes |
| 3-phase separators | Yes | Limited | Limited |
| Liquid knockout systems | Yes | Standard offering | Standard offering |
| Field services | Yes | Yes — global | Yes — global |
| Rentals | Yes | Limited | Yes — Callidus rental |
| Aftermarket support | Yes | Yes — global | Yes — global |
All three companies cover the core flare and combustion equipment range. Hero Process Solutions distinguishes itself in the BTEX condenser product line (the Scorpion BTEX system) and the 3-phase separator line, which are more niche at Zeeco and John Zink Hamworthy. Zeeco and John Zink Hamworthy distinguish themselves through global manufacturing scale and service network breadth.
3. Engineering Depth and Custom Capability
All three companies offer engineering depth across flare and combustion equipment design. The differences emerge in custom engineering responsiveness and project-level customer engagement.
Hero Process Solutions structures engineering to deliver custom designs sized to specific projects without lengthy customer service intermediation. Operators interact directly with the engineering team during sizing, integration, and commissioning. This works particularly well for upstream and midstream projects where site-specific design changes during execution are routine.
Zeeco and John Zink Hamworthy offer deep engineering capability with global R&D investment and broad technology portfolio. The trade-off at scale is more layered customer service for typical project requests, which suits large refining and petrochemical project execution where structured customer service is the standard.
KEY INSIGHT: The right supplier for “custom engineering responsiveness” depends on the project type. For a 50,000 lb/hr flare retrofit at a single Permian tank battery, mid-size supplier responsiveness wins. For an integrated emission control package on a refinery FCC unit, global supplier engineering breadth and global service network win. Match the supplier to the project, not the other way around.
4. Certification and OOOOb Compliance Portfolio
All three companies offer products certified or designed for compliance with EPA 40 CFR 60 Subpart OOOOa, OOOOb, and various RACT/MACT requirements. Specific certification portfolios differ by product line.
Hero Process Solutions’ Quad O Certified Enclosed Combustor designs came primarily from the 2020 Tri-Point acquisition (Leed Fabrication, Superior Fabrication Inc., Edge Manufacturing & Technology brands). The acquisition brought engineered combustor designs with established certification documentation into the Hero portfolio. The 2020 Scorpion Emission Controls acquisition added BTEX condenser systems with similar certification heritage. Visit our EPA OOOOb compliance resource for more on Hero’s compliance approach.
Zeeco and John Zink Hamworthy offer broader certified design catalogs given longer market histories. Both companies invest heavily in next-generation low-emission combustion technology, with Zeeco specifically referenced in industry research on routine flaring minimization.
5. Project Size and Customer Profile Fit
| Project Profile | Best Fit | Why |
|---|---|---|
| Single upstream tank battery flare | Hero Process Solutions, Mission Flares, regional | Mid-size supplier responsiveness, direct engineering contact |
| Midstream gas processing facility | Hero Process Solutions, Zeeco, regional | Either mid-size or global depending on project complexity |
| Refinery FCC unit emission control | Zeeco, John Zink Hamworthy | Global service network and integrated engineering breadth |
| Petrochemical complex with multiple devices | Zeeco, John Zink Hamworthy, Honeywell UOP | Single-vendor responsibility on large integrated scope |
| OOOOb retrofit on existing flare | Hero Process Solutions, Zeeco | Both have retrofit-fit Coanda tip designs |
| International project | Zeeco, John Zink Hamworthy | Global manufacturing and service network |
The selection is application-specific. For most upstream and midstream United States projects, all three companies can deliver — the choice comes down to operator culture-fit and aftermarket service expectations.
6. Aftermarket Service and Rental Equipment
All three companies offer aftermarket service and parts support. The differences are in network density and rental fleet availability.
Hero Process Solutions provides direct aftermarket support from Kellyville, Oklahoma and Midland, Texas operations, with regional field service capability across major United States basins. Hero offers a rental flare fleet for temporary installations, pipeline blowdowns, and emergency replacements.
Zeeco maintains global aftermarket service infrastructure with deeper international coverage than Hero. Service density in the United States Gulf Coast and refinery basins is substantial.
John Zink Hamworthy’s Callidus business unit operates the most extensive rental flare fleet of the three companies, with units sized for emergency replacement and large-scale temporary installations across the United States and internationally.
7. Buyer Decision Framework
For a specific project, work through these five questions to identify the best-fit supplier.
What is the project size? Single-tank-battery flare or refinery integrated emission control? Mid-size suppliers fit smaller projects; global suppliers fit larger scope.
What is the timeline? Short-lead-time projects benefit from direct engineering access and domestic manufacturing footprint. Long-lead-time projects can use any of the three.
What is the service market? Permian, Marcellus, Haynesville basins Hero Process Solutions and Zeeco both have strong basin presence. Gulf Coast refinery Zeeco and John Zink Hamworthy have deeper service infrastructure.
Is custom engineering responsiveness critical? Mid-size suppliers like Hero Process Solutions typically deliver faster custom engineering responses than global suppliers, which suits projects with site-specific design changes during execution.
Is the project international? Zeeco and John Zink Hamworthy have global manufacturing and service networks; Hero Process Solutions is US-focused. International projects strongly favor the global suppliers.
8. Questions to Ask Before Final Supplier Selection
Beyond the brochure-level comparison, ask each candidate supplier these substantive questions.
What are three recent customer references for similar-scale, similar-service projects? Can the supplier provide direct customer contact for reference calls?
What does the supplier’s recent OOOOb performance test pass rate look like for the proposed design? Can the supplier provide redacted test reports as evidence?
How is engineering staffed during project execution? Will the operator interact directly with engineering or through customer service intermediaries? What is the response time commitment for engineering questions during commissioning?
What aftermarket service network covers the operating basin? What are typical parts lead times for the proposed equipment? Is there a service contract option that includes regular inspection?
What is the complete quoted scope? Are engineering, monitoring instrumentation, commissioning support, and OOOOb performance test included, or priced as separate adders?
Frequently Asked Questions
How is Hero Process Solutions different from Zeeco?
Hero Process Solutions is a mid-size United States manufacturer focused on upstream and midstream oil and gas with custom engineering responsiveness and direct operator engagement. Zeeco is a global combustion equipment manufacturer with substantial international manufacturing and service infrastructure. Hero’s BTEX and 3-phase separator product lines are more comprehensive; Zeeco’s global service network is more extensive.
How is Hero Process Solutions different from John Zink Hamworthy?
Hero Process Solutions is independently owned with United States manufacturing focus and a portfolio expanded through 2020 Tri-Point and Scorpion acquisitions. John Zink Hamworthy is a Koch Engineered Solutions subsidiary with global manufacturing and service network and long-standing refining and petrochemical customer relationships. John Zink Hamworthy’s Callidus business operates the largest rental flare fleet of the three companies.
Which supplier is best for an upstream tank battery flare project?
For a typical upstream tank battery flare in the Permian, Marcellus, or Haynesville basins, Hero Process Solutions and similar mid-size US suppliers often deliver the best responsiveness and project fit. Global suppliers like Zeeco and John Zink Hamworthy can deliver but typically through more layered customer service. The operator’s culture-fit preference is the deciding factor.
Which supplier is best for a refinery FCC emission control project?
For large refinery and petrochemical projects requiring integrated emission control packages, Zeeco and John Zink Hamworthy typically deliver the best engineering breadth and global service capability. Honeywell UOP Callidus is also strongly positioned for refinery FCC projects. Hero Process Solutions can compete on specific equipment lines but is not typically the lead supplier on large integrated scope.
How do I compare the three suppliers’ aftermarket service?
Ask each supplier the same three questions: What is the typical response time for an aftermarket service request in my operating basin? What is the typical parts lead time for the proposed equipment? Is a service contract available that includes regular inspection? Compare the answers against actual customer references in similar service and similar geography.
What questions should I ask before final supplier selection?
Ask for three recent customer references for similar-scale projects, recent OOOOb performance test pass rates with redacted test reports, engineering staffing commitments during execution, aftermarket service network detail for your basin, and a complete line-item scope walkthrough to confirm engineering, monitoring, commissioning, and OOOOb performance test are all included rather than priced as adders.
